Hydrodynamic bearing runner for use in tilting pad thrust bearing assemblies for electric submersible pumps

ABSTRACT

An electrical submersible pump runner having a core layer and a wear layer affixed to the core layer. One embodiment of the invention provides an electrical submersible pump that includes a motor section and a centrifugal pump section. A seal section and rotary gas separator may also be included. The pump is powered by an electric cable that connects the pump, located in a bore hole, to a power source on the surface. A thrust runner coated with a wear layer (e.g., polymer) is provided in the motor and/or seal section to reduce bearing temperature, provide longer bearing life, reduce costs, and facilitate overhaul. The runner may also function as a rotating up-thrust bearing when the runner is coated with a wear layer on one side that is formed with a bearing geometry. In this case, the up-thrust bearing may be eliminated.

This application is a continuation of U.S. application Ser. No. 10/786,127 filed Feb. 26, 2004, now U.S. Pat. No. 7,163,368 which claims the benefit of U.S. Provisional Application Ser. No. 60/474,298, filed May 30, 2003, and U.S. Provisional Application Ser. No. 60/480,744, filed Jun. 24, 2003, which are all incorporated herein by reference in their entirety.

BACKGROUND

1. Field of the Invention

This invention relates to electrical submersible pumps, and more particularly to electrical submersible pumps that are powered by an electrical cable and have hydrodynamic (fluid film) thrust bearings in their motor section and in their seal section when employed.

2. Background of the Invention

Electric submersible pumps are used to lift liquids such as oil, water, or brine. They are typically long relative to their diameter to fit down drilled holes. For deep wells, a typical pump system consists of a multi-stage centrifugal pump, rotary gas separator, seal section, and motor. The motor is connected to an electric power source at the surface via electric cables. The rotor in the electric motor incorporates a tilting-pad hydrodynamic (fluid film) thrust bearing to support the rotor weight. The seal section prevents external well fluids from entering the motor and equalizes the pressure between the well fluid and internal motor lubrication oil. The seal section also houses up and down hydrodynamic tilting pad thrust bearings to react loads developed by the centrifugal pump.

For shallow wells such as those used to pump water from drilled holes for potable water, the seal and gas separator sections are eliminated. Tilting pad bearings are still used in the motor section.

For both deep and shallow well pumps, it is industry practice to manufacture the bearing pads of a relatively soft material and run them against a harder runner.

FIG. 5 illustrates the seal section portion of a known deep well submersible pumping system, produced by Baker Hughes of Houston, Tex. under the name Centrilift™. As shown, this seal section of the submersible pumping system includes a runner 550 between a down-thrust bearing 552 and an up-thrust bearing 554.

Tilting pad type hydrodynamic thrust bearings are also known from the present inventor's previous U.S. Pat. Nos. 4,676,668 to Ide, 5,137,373 to Ide, and 5,125,754 also to Ide, which are incorporated herein by reference in their entirety. In U.S. Pat. No. 5,137,373, the bearing can be formed in a single piece; in the other two patents, individual bearing pads are supported in a separate carrier.

In the context of a hydrodynamic thrust bearing, the stationary bearing pads face a rotating “runner” that is secured to (e.g., as by a key) or integrally formed with a shaft, in the presence of a lubricant (typically oil, but also water or a “process fluid”), which effectively separates the two components of the system via an elevated pressure developed at the interface as a result of hydrodynamic effects. For electric submersible pump seal sections, the direction of loading may be in two opposite directions. Hydrodynamic bearings are therefore spaced on both sides of the rotating runner.

In the prior art bearing/runner assemblies described in the aforementioned patents, the pads and runners are fabricated from dissimilar materials to preclude galling should the two components come into contact while under load (particularly at start-up, but also during overload conditions while running). In practice, the pads are, for example, either monolithic bronze, carbon, or fabricated from steel coated with a relatively “soft” non-ferrous material on the running surface, while the runners are typically hardened steel. Among the coatings used are engineered plastics. Industry practice is to apply the various coatings to the bearing pads.

SUMMARY OF THE INVENTION

In accordance with the present invention and contrary to the industry practice of applying the various coatings to the bearing pads, the present inventor has discovered that, in the case of engineered plastic coatings, commercial and performance advantages result from applying the coating to the runner rather than the pads. The pads are preferably uncoated hardened steel. The unexpected advantages resulting from the construction of the present invention include:

-   -   Only one component (i.e., the runner) of the bearing/runner         assembly is coated, rather than coating multiple components         (i.e., the pads, of which there are typically 5 to 10 per         assembly); this results in lower cost (including lower waste of         plastic in the molding process).     -   The swept area of wear surface (i e., plastic) is larger with         the runner coated and thus the wear rate under mixed/boundary         lubrication conditions is reduced, increasing bearing/runner         longevity.     -   The swept area of wear surface (i.e., plastic) is larger with         the runner coated and thus the surface temperature under         mixed/boundary lubrication conditions is reduced, increasing         bearing/runner longevity.     -   The bearing pads, when made of hardened steel, eliminate pad         wear. The less costly runner becomes the sacrificial component.         Since only the runner may need replacement, overhauls are less         complex and costly.     -   Recoating individual pads is not practical or economical;         recoating a runner is both economical and readily accomplished.     -   Conventional uncoated runners may be re-ground/re-lapped if the         design thickness tolerance permits, but plastic-coated runners         may be reworked indefinitely since only the worn plastic/bronze         interlayer is removed and replaced (the steel substrate remains         intact in the process).     -   The coating on one or both sides of the runner may be applied to         form a hydrodynamic bearing pad that rotates with the runner. In         this case, the rotating runner actually becomes the bearing and         the stationary “bearing” can be replaced by a simple flat plate.         In submersible pumps, this can provide a significant advantage.         In the pump bearing arrangement, the lower bearing normally         reacts operating loads while the upper bearing reacts transient         startup up-thrust loads only. By incorporating bearing pads on         the runner, the up-thrust bearing can be eliminated.

Thus, an embodiment of the present invention provides an electrical submersible pump shaft and bearing combination including a generally cylindrical shaft having a runner formed or secured thereon. In accordance with an important aspect of the invention, the runner that is supported by the bearing pads is provided with a surface layer of engineered plastic such as polyimide or other polymer coatings. As used herein, an engineered plastic refers to a plastic (e.g., polymer) having high performance characteristics such as high strength, high temperature capability, chemical resistance, and heat resistance. The plastic is engineered to provide the properties required for a particular application. Additional materials can also be added to provide other material characteristics, such as adding Teflon™ and/or graphite to reduce coefficients of friction. Examples of engineered plastics include polyimide, PEEK, nylon, PTFE, and polyamidimide. Naturally, other materials may be used, provided that the chosen material has the required support and wear characteristics. In the currently preferred embodiment, an engineered plastic layer such as polyimide is provided on a sintered bronze layer.

Applying the bronze layer and the polyimide layer to the runner yields advantages similar to those achieved in prior art bearing/runner assemblies in which engineered plastic coatings are applied to the bearing pads. In particular, the plastic layer provides a wear surface so as to avoid damage to the pad during start-up. The wear surface allows the pad to withstand wear caused during start-up. By providing a wear surface, the bearing assembly operates in two modes. First, at initial startup, the bearing assembly acts as a wear bearing wherein the coated runner shaft rubs against the pad surface. After start-up, the bearing assembly operates hydrodynamically and there is little or no contact between the shaft and bearing pad surface.

Importantly, however, applying the bronze layer and the polyimide layer to the runner yields advantages beyond those of prior art bearing/runner assemblies in which engineered plastic coatings are applied to the bearing pads. To begin with, coating a runner is cheaper than coating bearing pads. In addition, the bearing pads may be constructed of hardened steel, which in turn prolongs their life. Thus, the more expensive component of the bearing/runner system is constructed with the longest life and the cheaper item of the two is constructed as a replaceable wear item. Also, the runner is a much simpler component (e.g., a disc), thus allowing for fairly simple retrofitting to existing systems. Normally, runners are manufactured of heat treated and often expensive materials. By using such a polymer coating, the runner itself may be manufactured of less expensive, and more easily machined mild steel.

Another advantage of the present invention is that the steel substrate can conduct heat away from the polymer (considered an insulator) better than a conventional polymer-coated bearing pad due to the greater surface area of the runner in comparison with the surface area of the bearing pad(s). Also, by coating the runner, there is more polymer surface area to wear than if the pads themselves are coated. This may extend the bearing/runner life when mixed lubrication occurs. For the case where the coating forms a hydrodynamic bearing pad on the runner surface, one of the pump bearings can be eliminated.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a partial sectional view of a runner according to an exemplary embodiment of the present invention.

FIG. 2 is a sectional view of the runner of FIG. 1 in combination with a shaft and bearing assembly.

FIG. 3 is a partial sectional view of a runner with hydrodynamic bearing pads on one side, according to an embodiment of the present invention.

FIG. 4 is a plan view of the runner of FIG. 3 showing the bearing pads on the runner face.

FIG. 5 is a sectional view of a seal section portion of a prior art deep well submersible pumping system.

DETAILED DESCRIPTION OF THE INVENTION

Embodiments of thrust bearing runners are described in this detailed description of the invention. In this detailed description, for purposes of explanation, numerous specific details are set forth to provide a thorough understanding of embodiments of the present invention. One skilled in the art will appreciate, however, that embodiments of the present invention may be practiced without these specific details. In other instances, structures and devices are shown in block diagram form. Furthermore, one skilled in the art can readily appreciate that the specific sequences in which methods are presented and performed are illustrative and it is contemplated that the sequences can be varied and still remain within the spirit and scope of embodiments of the present invention.

In an embodiment of the present invention, FIG. 1 shows a bi-directional runner 100 having a bronze layer 102 (e.g., sintered bronze layer) and a wear layer 104 (e.g., made of an engineered plastic such as polyimide). In this example, runner 100 is a keyed steel runner with copper electroplating. Although runner 100 is depicted as a bi-directional runner, it is also possible to construct a uni-directional runner having the bronze layer 102 and layer 104 only on one side. In prior art bearing/runner assemblies, engineered plastic coatings may be used on tilt pad thrust bearings, but the plastic has invariably been applied to the bearing pads. By applying the bronze layer 102 and layer 104 to the runner, many advantages may be achieved.

To achieve this construction, runner 100, which may be a core layer made of steel, for example, is plated with a copper alloy. Runner 100 then has the porous bronze layer 102 added, for example, in a sintering process. After bronze layer 102 is in place on runner 100, layer 104 may be added, for example, by an injection molding process. In this manner, the material of layer 104 (e.g., polyimide) may flow into the porous areas of bronze layer 102, thus creating a wear surface firmly anchored to runner 100. In addition to polyimide, layer 104 may be made of other materials having suitable PV (pressure-times-velocity) values, such as polysultone and polyphenylene sulfide. Materials with a high PV value can withstand higher loads. and higher speeds those with a lower PV value. In addition to injection molding, layer 104 may be affixed to runner 100 by other means, such as mechanical fastening or adhesives.

Applying the bronze layer and the polyimide layer to the runner yields functional advantages similar to those achieved in prior art bearing/runner assemblies in which engineered plastic coatings are applied to the bearing pads. In particular, the plastic layer provides a wear surface so as to avoid damage to the pad during start-up. The wear surface allows the pad to withstand wear caused during start-up. Even with a relatively rigid support structure, the assembly can be designed to achieve hydrodynamic operation during steady state conditions, but the wear characteristics at start-up can cause a potential concern. By providing a wear surface, the bearing assembly operates in two modes. First, at initial start-up, the bearing assembly acts as a wear bearing, wherein the coated runner shaft rubs against the pad surface. After start-up, the bearing assembly operates hydrodynamically, and there is little or no contact between the shaft and bearing pad surface.

By affixing the wear layer 104 to runner 100 rather than the bearing pads, further significant advantages may be achieved. For example, coating a runner is cheaper than coating bearing pads. In addition, the bearing pads may be constructed of hardened steel, which in turn prolongs their lives. Thus, the more expensive component of the bearing/runner system is constructed with the longest life and the cheaper item of the two is constructed as a replaceable wear item. Also, the runner is a much simpler component (e.g., a disc), thus allowing for fairly simple retrofitting to existing systems. Normally, runners are manufactured of heat-treated and often expensive materials. By using such a polymer coating, the runner itself may be manufactured of less expensive, and more easily machined mild steel.

Another advantage of the present invention is that the steel substrate may conduct heat away from the polymer (considered an insulator) better than a conventional polymer-coated bearing pad, due to the greater surface area of runner 100 in comparison with the surface area of the bearing pad(s). Also, by coating runner 100, there is more polymer surface area to wear than if the pads themselves are coated. This may extend the bearing/runner life when mixed lubrication occurs.

FIG. 2 depicts runner 100 in combination with bearing pads 300 and a shaft 200, according to an embodiment of the present invention having bi-directional up and down thrust. In this example, runner 100 is a keyed steel runner with copper electroplating.

FIG. 3 shows a runner 400 on which bearing pads 401 are molded on one side of the runner 400, according to an embodiment of the present invention. Holes or passageways 402 connect the pads 401 to the runner surface 403 so that the plastic can be injection molded in one operation. The holes 402, as well as undercuts 404, provide mechanical locks to hold the plastic of pads 401 and surface 403 in position. Optionally, instead of holes or undercuts, simple recesses or cavities could be provided in the surface of runner 400 into which plastic could be molded to form the pads 401. The bearing 500 is shown as a simple plate. FIG. 4 shows the runner 400 and bearing pads 401 in plan view.

The foregoing disclosure of the preferred embodiments of the present invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise forms disclosed. Many variations and modifications of the embodiments described herein will be apparent to one of ordinary skill in the art in light of the above disclosure. The scope of the invention is to be defined only by the claims appended hereto, and by their equivalents.

Further, in describing representative embodiments of the present invention, the specification may have presented the method and/or process of the present invention as a particular sequence of steps. However, to the extent that the method or process does not rely on the particular order of steps set forth herein, the method or process should not be limited to the particular sequence of steps described. As one of ordinary skill in the art would appreciate, other sequences of steps may be possible. Therefore, the particular order of the steps set forth in the specification should not be construed as limitations on the claims. In addition, the claims directed to the method and/or process of the present invention should not be limited to the performance of their steps in the order written, and one skilled in the art can readily appreciate that the sequences may be varied and still remain within the spirit and scope of the present invention. 

1. A rotating electrical submersible pump runner for contacting a bearing in a pad-type hydrodynamic bearing/runner assembly, the rotating runner comprising: a core layer; an intermediate layer sintered to the core layer; and a wear layer injection molded to the intermediate layer, wherein the wear layer comprises an individual pad applied at a discrete location on a side of the rotating runner facing the bearing such that a remaining portion of the side of the rotating runner facing the bearing is exposed, and wherein the individual pad protrudes above the exposed remaining portion a predetermined height such that the individual pad is configured to contact the bearing with the exposed remaining portion spaced apart from the bearing.
 2. The runner of claim 1, wherein the intermediate layer defines pores, and wherein portions of the wear layer are disposed within the pores of the intermediate layer.
 3. The runner of claim 1, wherein the rotating runner comprises a disc.
 4. The runner of claim 1, wherein the core layer comprises steel.
 5. The runner of claim 4, wherein the steel is not heat-treated.
 6. The runner of claim 1, wherein the core layer comprises steel with copper electroplating.
 7. The runner of claim 1, wherein the wear layer comprises one of polyimide, PEEK, nylon, PTFE, polyamid-imide, polysultone, and polyphenylene sulfide.
 8. The runner of claim 1, wherein the core layer defines a recess into which the wear layer is injection molded.
 9. The runner of claim 8, wherein a cross-section of the recess has an opening and a base, and wherein the base is larger than the opening.
 10. The runner of claim 8, wherein the wear layer protrudes from the recess above the core layer.
 11. The runner of claim 1, wherein the core layer has a first face and a second face opposite to the first face, wherein the intermediate layer is a first intermediate layer and the wear layer is a first wear layer, wherein the first intermediate layer and the first wear layer are disposed on the first face, and wherein the runner further comprises a second intermediate layer sintered to the second face of the core layer, wherein the second intermediate layer defines pores; and a second wear layer injection molded to the second intermediate layer, wherein portions of the second wear layer are disposed within the pores of the second intermediate layer.
 12. The runner of claim 11, wherein the second wear layer defines a plurality of individual bearing pads.
 13. The runner of claim 1, wherein the wear layer defines a plurality of spaced bearing pads to provide a bearing that rotates with the runner.
 14. A rotating electrical submersible pump runner for use in a pad-type hydrodynamic bearing/runner assembly, the rotating runner comprising: a core layer; an intermediate layer sintered to the core layer; and a wear layer injection molded to the intermediate layer, wherein the core layer has a first face and a second face opposite to the first face, wherein the intermediate layer is a first intermediate layer and the wear layer is a first wear layer, wherein the first intermediate layer and the first wear layer are disposed on the first face, and wherein the runner further comprises: a second intermediate layer sintered to the second face of the core layer, wherein the second intermediate layer defines pores, and a second wear layer injection molded to the second intermediate layer, wherein portions of the second wear layer are disposed within the pores of the second intermediate layer, and wherein the core layer defines a passageway through which the first wear layer and the second wear layer are connected.
 15. A rotating electrical submersible pump runner for contacting a bearing in a pad-type hydrodynamic bearing/runner assembly, the rotating runner comprising: a core disc having a first side and a second side opposite to the first side; a first polymer coating affixed to the first side of the core disc; and a second polymer coating affixed to the second side of the core disc, wherein the second polymer coating forms a plurality of individual bearing pads, wherein each individual bearing pad of the plurality of bearing pads is applied at a discrete location on the second side of the core disc such that a remaining portion of the second side is exposed, and wherein the each individual bearing pad protrudes above the exposed remaining portion of the second side a predetermined height such that the each individual bearing pad is configured to contact the bearing with the exposed remaining portion of the second side spaced apart from the bearing.
 16. The runner of claim 15, wherein the core disc comprises a core layer and a porous bronze intermediate layer sintered to the core layer, wherein the intermediate layer defines pores, and wherein portions of the first polymer coating are disposed within the pores of the intermediate layer.
 17. The runner of claim 16, wherein the first polymer coating is injection molded to the intermediate layer.
 18. The runner of claim 15, wherein the core disc comprises a core layer and a porous bronze intermediate layer sintered to the core layer, wherein the intermediate layer defines pores, and wherein portions of the second polymer coating are disposed within the pores of the intermediate layer.
 19. A rotating electrical submersible pump runner for contacting a bearing in a pad-type hydrodynamic bearing/runner assembly, the rotating runner comprising: a core disc having a first side and a second side opposite to the first side; a first polymer coating affixed to the first side of the core disc; and a second polymer coating affixed to the second side of the core disc, wherein the second polymer coating forms a plurality of individual bearing pads, wherein the core disc defines a passageway through which the first polymer coating is connected to the second polymer coating.
 20. A bearing and runner assembly for use in a submersible pump system, the assembly comprising: a bearing comprising at least one bearing pad; and a runner comprising a core layer, a porous intermediate layer sintered to the core layer, wherein the intermediate layer defines pores, and a wear layer injection molded to the intermediate layer, wherein portions of the wear layer are disposed within the pores of the intermediate layer, wherein the wear layer comprises an individual pad applied at a discrete location on a side of the runner facing the bearing such that a remaining portion of the side of the runner facing the bearing is exposed, and wherein the individual pad protrudes above the exposed remaining portion a predetermined height such that the individual pad is configured to contact the bearing with the exposed remaining portion spaced apart from the bearing, wherein the at least one bearing pad is adapted to contact at least a portion of the wear layer. 